Head Scratcher After Engine Rebuild - Won't even crank!
 

Hi all.

I've got an odd one, that probably and hopefully has an obvious solution! I've just finished a forged rebuild that took around 5 months to complete. I got it all back together and the car won't even crank. Firstly I thought the battery so we jumped it from another car, no joy, then I thought starter so replaced it with a new one today, still no joy.

When I turn the ignition all the signs are good, the dash dials come on etc, the starter solenoid clicks but the motor does not spin and the alarm just beeps. This happens with the car full assembled and jumped from a running car with the same power battery (61Ah). Even when the motor is not fully in the t/m, so free to spin should it want to, it doesn't. Video attached.

The car is a UK spec 2006 Hawk STi.

Any thoughts?

Cheers!

VIDEO: https://drive.google.com/open?id=0By...HdBc1FxUmQtc3c

Where is the earth lead on the starter, they have a 90 deg bracket on the top starter motor bolt with the earth on that, cannot see it in the vid.

aye, we just clocked that to! rebuilding it now....

Cheers!

ok, so step in the right direction, at least it's cranking now! But not starting, comes up with 3 codes for (2 for MAF sensor and 1 for crankshaft pos sensor) all connectors are connected.

Also do you know where this earthing lead is meant to go? It is attached to the turret and attached the other end to the RHS rocker cover as there was some purple on the connector and a tiny bit of purple something on the rocker cover, but not sure where it came from!

https://cimg4.ibsrv.net/gimg/www.sco...3b8d009d03.jpg

Cheers

Totally off topic, but as I'll soon be in the same position myself; you have remembered to prime it with oil, haven't you? :)

I'm worried I might get all excited when the engine is in and forget this vital step... kid in a sweet shop, me.

Yeah after nearly 5 months of driving a c1 to work, that's about the size of it!

"Prime the oil" by which do you mean cranking it over with fuel pump and plugs removed? In which case yes lots. However I have fitted a oil pressure gauge with an extended and the dial just reads 150 when cranking, but maybe that's normal.

When everything is attached again and cranking there is no smell of fuel so I'm thinkng fuel isn't getting in for some reason. Not had chance this evening to investigate but will tomorrow...

Yes, that's what I meant :)

more knowledgeable folks will hopefully be along shortly, but off the top of my head what I'd check is:

- Can you hear the pump prime when you turn the ignition on?

- Do you get a spark?

Is the alarm still chirping or has the engine earth strap cured that?

Did you rebuild the original engine or a donor engine e,g CDB, the early engines had a different pick up pattern on the crankshaft sprocket for the sensor. So if you've used an early cdb that may be why you're getting the cel code.

to all, thanks for the help. This is where I am now:

a) got oil pressure. I removed the plugs and oil filter and cranked in batches until oil dripped out then refitted the filter, and now at least I have oil pressure when cranking that turns off the light.
b) got no spark and no fuel flow
C) error codes for crank sensor and maf sensor switch live when cranking

Engine is a rebuild of my old one and uses the same crank sensor. Thinking I might buy a new sensor. Does anyone know if the engine detects crank sensor failure that it pulls spark and fuelling, thay sort of makes sense as the ecu has no idea where I the cycle the crank is?

Check that you have not bent any of the terminals in the brown and black plugs behind the battery...Ive seen that before.

Normally bolts to the crash rail which covers the fuel injectors.
Have you checked the small earth leads which bolt to the top of the Inlet manifold each side.
Check the coil pack connectors - black to rear coils, white to front coils.

Hope this helps

Maybe wrong connectors fitted possibly injector and crank i think or cam sensor.

No body near by that could let you swap over their sensors to try? It's a 2 min job

Thanks for the suggestions, annoyingly it won't be till Sunday before I can check it out!

I had a similar problem when my engine was built but the issue was the wrong crank pulley, newage block in a classic. I know you don't have the same problem but I understand how frustrating it is when you don't know the problem. Hope you get it sorted mate

Have you checked the pins in the plug on the crank sensor? I had a similar issue when refitting my engine last time and the wire had pulled out the back of the plug to the sensor

It's Alive!

:)

One of the pins of the crank sensor had bent over when I put the connector on... doh!

Thanks for all the suggestions!

Great news.